Less-Lethal Ballistic Projectile Launcher

ABSTRACT

The light-weight handheld less-lethal ballistic projectile launcher is configured as an “over/under” double barrel handheld device with a “break open” loading action. The launcher includes a barrel section pivotally connected to receiver section. The barrel section pivots between an open load/unload position and a closed firing position. The barrel section includes two metal barrel sleeves that are press fit into axial bores formed in the body of the barrel section. The barrel section also includes an ejector, which locks the barrel section in the closed firing position and partially expels spent rounds from the barrel sleeves when the barrel section is opened. The receiver section houses the launcher&#39;s fire control mechanism. The fire control mechanism uses a traditional single action operation and ensures that rounds are alternatively discharged from each barrel and prevents rounds from both barrels from being discharged simultaneously.

This is a divisional application of U.S. patent application Ser. No.14/302,518 filed Jun. 12, 2014, which is a divisional application ofU.S. patent application Ser. No. 12/924,510 filed Sep. 29, 2010, whichis now U.S. Pat. No. 8,782,938 issued Jul. 22, 2014, and which claimspriority on U.S. Provisional Patent Application Ser. No. 61/247,286filed on Sep. 30, 2009.

This invention relates to less-lethal weapons and in particular handheldless-lethal ballistic projectile launchers.

BACKGROUND OF THE INVENTION

Less-lethal projectile weapons provide law enforcement and militarypersonnel with an alternative to firearms in hostile encounters. Whilefirearms are necessary and appropriate for adjudicating deadly forceencounters, less-lethal projectile weapons afford law enforcement andmilitary personnel a tool, which can be effectively used across abroader range of the use of force spectrum. A suspect can beincapacitated by the blunt force impact of a projectile shot from aless-lethal weapon with less risk of serious injury to the suspectwithout exposing the officer or soldier to undue danger.

Less-lethal projectile weapons shoot a variety of projectiles, includingbean bags, rubber slugs, rubber shot, and wood dowels. Compared to thelethal loads and bullets fired from conventional firearms, these bluntforce impact projectiles are much larger, softer and travel at muchslower velocities from the less-lethal projectile weapons so that theydo not produce lethal penetrating wounds. Less-lethal projectilesweapons typically fall into two categories: specialized launchers thatuse compressed air to propel the projectiles and conventional firearmsconverted to use specialized ballistic projectile ammunition.

The compressed air launchers require a compressed air source, usually acannister, as well as specialized projectile rounds. Compressed airlaunchers are generally bulky and inconvenient to carry and deploywithout additional specialized slings, holsters and pouches, whichfurther occupy the limited space on the officer's duty belt or asoldier's equipment rig. The use of compressed air launchers alsorequire specialized training and additional tactics to effectivelydeploy.

Conventional firearms that are converted to shoot specialized ballisticprojectile ammunition present other drawbacks and potential problems.Special ballistic projectile rounds have been developed for use inconventional 12 gauge shotguns, such as the Remington 870 and Mossberg500. These less-lethal projectile rounds, use a standard 2½″ 12 gaugeshell with a small charge that propels a bean bag, wood dowel, rubberslug or rubber shot. While other firearms have been converted to useother calibers of rounds, the 12 gauge shotgun shell generally providesthe most suitable round for less-lethal projectile ballistic and is verycost effective. While convenient, there is a potential for confusionbetween less-lethal projectile rounds and conventional lethal ammunitionrounds in a stressful tactical situation. Another drawback to convertedshotguns is their size and weight. Shotguns are large weapons thatgenerally require both hands to manipulate. Shotguns must be held orslung, rather than simply holstered.

SUMMARY OF THE INVENTION

The present invention provides light-weight handheld less-lethalballistic projectile launcher. One embodiment of this invention isconfigured as an “over/under” double barrel handheld device with a“break open” loading action. This launcher includes a barrel sectionpivotally connected to a receiver section. The barrel section pivotsbetween an open load/unload position and a closed firing position. Thebarrel section includes two metal barrel sleeves that are press fit intoaxial bores formed in the body of the barrel section. The barrel sectionalso includes an ejector, which locks the barrel section in the closedfiring position and partially expels spent rounds from the barrelsleeves when the barrel section is opened. The receiver section housesthe launcher's fire control mechanism. The fire control mechanism uses atraditional single action operation and ensures that rounds arealternatively discharged from each barrel and prevents rounds from bothbarrels from being discharged simultaneously. Only less-lethal ballisticprojectile rounds specifically designed for use with this one embodimentof launcher can be loaded or used, while other embodiments may acceptstandard less-lethal ballistic projectile rounds, but not conventionalammunition.

Accordingly, the present invention provides several advantages overcompressed air launchers and conventional firearms that are convertedfor less-lethal ballistic projectile rounds. The handgun configurationallows the launcher to be manipulated, held and fired with one hand, aswell as being conveniently carried and holstered. The over/under doublebarrel configuration provides a two shot capacity. The bodies of thereceiver and barrel sections are constructed of reinforced polymermaterials for durability and low weight. The break-open load action andejector allows the launcher to be easily loaded and unloaded. Theejector provides a dual function in that it locks the barrel section inthe firing position and pulls the spent rounds from the barrel sectionto ease reloading. The fire control mechanism provides simplicity ofoperation and reliability. The design and configuration of the barreland receiver sections ensures that the launcher only operates usingmating less-lethal projectile rounds and cannot be loaded or used withdeadly conventional ammunition. In other embodiment of the launcher, theback plate can be modified to accommodate standard less-lethalprojectile rounds as desired.

These and other advantages of the present invention will become apparentfrom the following description of an embodiment of the invention withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate an embodiment of the present invention, inwhich:

FIG. 1 is a perspective view of an embodiment of the less-lethalballistic projectile launcher of this invention;

FIG. 2 is a right side view of the launcher of FIG. 1;

FIG. 3 is a right side view of the launcher of FIG. 1;

FIG. 4 is a top view of the launcher of FIG. 1;

FIG. 5 is a bottom view of the launcher of FIG. 1;

FIG. 6 is a front view of the launcher of FIG. 1;

FIG. 7 is a back view of the launcher of FIG. 1;

FIG. 8 is an exploded view of the launcher of FIG. 1;

FIG. 9 is a perspective view of the ejector used in the launcher of FIG.1;

FIG. 10 is a perspective view of the back plate of the launcher of FIG.1;

FIG. 11 is a perspective view of the mating less-lethal ballisticprojectile round used in the launcher of FIG. 1;

FIG. 12 is a partial side sectional view of the less-lethal ballisticprojectile round of FIG. 11 taken along line 12-12;

FIG. 13 is a side view of the launcher of FIG. 1 showing the ejectorbeing pulled forward;

FIG. 14 is a side view of the launcher of FIG. 1 showing the barrelsection moving to the open loading position;

FIG. 15 is a side view of the launcher of FIG. 1 showing less-lethalrounds being loaded into the barrel sleeves;

FIG. 16 is a partial side sectional view of the launcher of FIG. 1 withthe barrel section in the open loading position showing the matingless-lethal projectile rounds loaded within the barrel sleeves;

FIG. 17 is a partial side sectional view of the launcher of FIG. 1 withthe barrel section in the closed firing position showing the matingless-lethal projectile rounds loaded within the barrel sleeves;

FIG. 18 is a partial side sectional view of the launcher of FIG. 1 withnon-mating less-lethal projectile rounds loaded within the barrelsleeves, which prevent the barrel section from being closed;

FIG. 19 is a side view of the launcher of FIG. 1 showing spentless-lethal rounds being pulled from the barrel sleeves;

FIG. 20 is a side view of the launcher of FIG. 1 with a portion cut awayto show the internal working parts of the launcher in a “safe/load”mode;

FIG. 21 is a side view of the launcher of FIG. 1 with a portion cut awayto show the internal working parts of the launcher in a “cocked” modewith the rocker in a upper barrel firing position;

FIG. 22 is a side view of the launcher of FIG. 1 with a portion cut awayto show the internal working parts of the launcher discharging the roundfrom the upper barrel sleeve;

FIG. 23 is a side view of the launcher of FIG. 1 with a portion cut awayto show the internal working parts of the launcher in “cocked” mode withthe rocker in a lower barrel firing position;

FIG. 24 is a side view of the launcher of FIG. 1 with a portion cut awayto show the internal working parts of the launcher discharging the roundfrom the lower barrel sleeve;

FIG. 25 is a side view of the launcher of FIG. 1 with portion cut awayto show the internal working parts of the launcher in “safe/load” modewith expended rounds ready to be ejected;

FIG. 26 is a simplified sectional view of the fire control mechanismused in the launcher of FIG. 1 showing the rocker striking the firingpin of the upper barrel sleeve; and

FIG. 27 is a simplified sectional view of the fire control mechanismused in the launcher of FIG. 1 showing the rocker striking the firingpin of the lower barrel sleeve.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, FIGS. 1-27 show one embodiment of theless-lethal launcher of this invention, which is designated generally asreference numeral 10. In this embodiment, launcher 10 is configured as ahandheld “over/under” double barrel less-lethal weapon. The doublebarrel configuration provides launcher 10 with a two shot capacitybefore reloading is required. Although, launcher 10 is illustrated withan “over/under” double barrel configuration, single barrel and othermultiple barrel embodiments, such as “side-by-side double barrel”configurations are contemplated within the teachings of this invention.Launcher 10 also uses a “break open” loading action where the barrelsection pivots away from the receiver so that rounds can be loadeddirectly into the barrels. Again, although a break open loading actionis illustrated and described other embodiments may employ other loadingactions and mechanisms.

Although other embodiments of this invention may be configured for usewith conventional less-lethal ballistic projectile rounds, launcher 10is specifically designed to be used only with specialized matingless-lethal projectile rounds and is inoperable with other less-lethalrounds and conventional lethal ammunition. These mating less-lethalprojectile rounds can be loaded with a variety of blunt forceprojectiles, such as but not limited to, bean bags, rubber slugs, rubbershot, and wood dowels. FIG. 11 shows an embodiment of the matingless-lethal projectile rounds 2 of launcher 10. Round 2 has an annularrecess 5 formed around the primer 6 on the back of the shell casing 4.

As shown, launcher 10 generally includes a barrel section 20 located atthe fore or distal end of the launcher and a receiver section 40 locatedat the aft or proximal end of the launcher. Receiver section 40 isconfigured in the shape of a conventional handgun frame and includes ahandle grip 42 and trigger guard 44. Barrel section 20 is pivotallyconnected to receiver section 40 by roll pin 48. Barrel section 20pivots between an open “load/unload” position where the rear end of thebarrel section is pivoted away from receiver section 40 (FIG. 15) and aclosed “fire” position where the rear of the barrel section abutsreceiver section (FIG. 13). Barrel section 20 has a forward end fromwhere projectiles exit launcher 10 and a rear end where less-lethalballistic projectile rounds are loaded into the barrel section. Bothbarrel section 20 and receiver section 40 are formed, molded orotherwise constructed from a durable, light weight polymer plastic orother composite material. Other suitable materials may be used includingfiberglass reinforced nylon, but the materials used in the bodies ofbarrel section 20 and receiver section 40 are generally selected to beimpact, heat and solvent resistant in addition to being durable andlight weight.

Barrel section 20 includes two barrel sleeves 22 and 22′ press fit intoaxial bores formed in the body of barrel section 20 in an “over-under”configuration. Each barrel sleeve 22 and 22′ is a length of tubularsteel, aluminum or other suitable metal. Each barrel sleeve 22 and 22′has a axial bore that runs their entire length. Each barrel sleeve 22and 22′ has a first diameter A and a second diameter B. The firstdiameter A is nearest the rear end of the barrel sleeves and is largerthan the second diameter B. There is a tapered shoulder or chock 24 thattransitions between diameters A and B. Taper shoulder 24 is spaced 2½inches from the rear end of each barrel sleeve. It should be noted that2¾ inch shells, which are the standard length for conventional 12 gaugeammunition with lethal loads, will protrude from rear end of barrelsleeves and prevent barrel section 20 from closing into the firingposition, because the length of first diameter 23 is not long enough toaccommodate such shells and will protrude from the barrel section 20.Consequently, the configuration of barrel sleeves 22 and 22′ operativelyprevents launcher from being used with standard lethal ammunition.

As best shown in FIG. 8, receiver section 40 houses the launcher's firecontrol mechanism 50. Fire control mechanism 50 uses a traditionalsingle action operation, where the user must manually “cock” the hammerbefore the trigger can be pressed to discharge the less-lethal round.Fire control mechanism 50 also ensures that rounds are alternativelydischarged from each barrel and prevents rounds from both barrels frombeing discharged simultaneously.

The working parts of fire control mechanism 50 are disposed within thereceiver section 40 and held in place by a side cover plate 46 attachedto the section with screws 47. The main working parts of fire controlmechanism 50 include: two firing pins 52, a trigger 60, a hammer 70, arocker 80 and rocker spur 90. Each firing pin 52 is disposed in bores inreceiver section 40 and biased by a spring 54. Both firing pins 52 areretained within receiver section 40 behind back plate 56, which is heldto receiver section 40 by screws 57. As best shown in FIG. 10, backplate 56 has a curved rib 58 that protrudes from its face above eachfiring pin 52. Trigger 60 is pivotally connected to receiver section 40by roll pin 62 and biased by trigger spring 64 seated in a bore withinreceiver section 40. Trigger 60 also includes a pawl 66. Hammer 70 ispivotally connected to receiver section 40 by roll pin 71. Hammer 70 hasa hammer spur 72 and a pair of edges or sear notches 73 and 75, whichprovide the sear function of the fire control mechanism and operativelyreceive pawl 66 of trigger 60. Hammer spring 74 and strut pin 76 areseated within a bore descending into the grip area of receiver section40. Hammer spring 74 urges hammer 70 forward toward barrel section 20.Rocker 80 is carried within a recessed pocket 79 in hammer 70 and ispivotally connected to hammer 70 by roll pin 81. Rocker 80 is also urgedforward by spring 82 which is seated in a bore in the rear edge ofrocker 80 and compressed against the inner edge 78 of hammer 70. Rocker80 has an arc side that provides two spaced strike faces (an upperstrike face 84 and a lowers strike face 86). Rocker spur 90 is carriedby hammer 70 and rotatably connected to the hammer by roller pin 91,which pivotally connects the hammer to receiver section 40. As shown,rocker spur 90 has a cover leaf shape with four lobes 92. Each lobe 92has a top contact edge 93 and a side contact edge 95, which converge toform a corner rocker stop 94. Rocker spur 90 is biased by a leaf spring96 which is seated within an elongated pocket 97 formed in the handlearea of receiver section 40.

Barrel section 20 also includes an ejector 30 that is slidably heldwithin the barrel section. As best shown in FIG. 9, ejector 30 has across member 31 and two parallel legs 32 that slide within alongitudinal slot 21 formed in the sides of barrel section 20. One ofthe legs 32 has a threaded through bore 35 for receiving a retainingscrew 34. On the side of barrel section 20 as the ejector leg 32 havingretaining screw 34, a secondary slot 27 is formed so that the retainingscrew extends through the leg into the secondary slot and limits thetravel of ejector 30 to the length of that secondary slot. Ejectorsprings 35 inserted into bores 29 in barrel section 20 urge ejector 30out of the rear end of the barrel section. Tabs 36 extend outwardly fromthe sides of each leg 32. Cross member 31 has rounded grooves 33 forreceiving the shell casing flanges of the less-lethal rounds. Crossmember 31 also has a pair of nubs 38 that protrude rearward opposite oflegs 32. Each nub 38 has a chamfer 39 on its lower edge. In the firingposition, nubs 38 fit into side notches 59 formed in back plate 56locking barrel section 20 in the closed firing position. Springs 35exert a constant force on ejector 30 to keep nubs 38 seated withinnotches 59, thus maintaining barrel section 20 in the closed firingposition. When a user wishes to open the launcher moving the barrelsection to the loading position, the user will push forward on tabs 36of ejector 30. The forward movement of ejector 30 retracts nubs 38 fromnotches 59 allowing barrel section 20 to pivot forward to the loadingposition.

FIGS. 13-19 illustrate how launcher 10 is manually loaded and unloaded.It should be noted that launcher 10 cannot be loaded without hammer 70being pulled into the “pre-cocked” position placing the launcher in the“safe/load” mode. Pulling hammer 70 to the pre-cocked positions pullsrocker 80 from contact with either of the firing pins 52, so that around cannot be inadvertently discharged when barrel section 20 is swungback to the closed fire position. The user pulls ejector 30 forward(FIG. 13) and swings barrel section 20 to the open position (FIG. 14).Once barrel section 20 is in the open load/unload position, the user canmanually insert the mating less-lethal projectile rounds 2 into eachbarrel sleeve 22 (FIG. 15).

When barrel section 20 is loaded with mating rounds 2 and closed in thefiring position (FIG. 17), ribs 58 of back plate 56 seats within annularrecess 5 of rounds 2. Ribs 58 are specifically positioned and configuredon back plate 56 so that only the specially mating less-lethalprojectile rounds can be used in launcher 10. As shown in FIG. 18, ribs58 would prevent barrel section 20 from being closed when loaded with anon-mating less-lethal round or conventional ammunition. In otherembodiments of this invention, the back plates and mating less-lethalprojectile rounds may configured with other mating structures within theteachings of this invention. By way of example as shown in FIGS. 28-30,back plate 100 may includes a pair of pintle 102 which seat within theannular recess 5 of mating less-lethal projectile rounds 2.

It should be further noted that when rounds 2 are inserted into barrelsleeves 22, the flanges of shell casings 4 partially seat within thegrooves 33 of ejector 30. Once rounds 2 have been spent, the user againpulls ejector 30 forward and swing barrel section 20 to the openload/unload position (FIG. 14). When barrel section 20 is opened, thespent rounds 2 are partially expelled from the barrel sleeves by ejector30, which is urged rearward by springs 35. Round grooves 33 in crossmember 31 catch flanges 6 of the shell casings 4 and partially expel thespent rounds from the rear end of barrel section 20.

FIGS. 20-27 illustrate the operation of fire control mechanism 50 oflauncher 10. FIG. 20 shows launcher 10 in an initial “safe/pre-cock” or“safe/load” mode with the mating less-lethal projectile rounds 2inserted into barrel sleeves 22 and 22′, and with barrel section 20locked in the closed firing position. In the “safe” mode, trigger pawl66 restrictively seats within sear notch 73, which prevents the userfrom pressing the trigger and discharging either of rounds 2. It shouldbe noted that in the safe mode, both strike faces 84 and 86 of rocker 80are physically spaced from firing pins 52. The bottom of rocker 80 restson top contact edge 93 of one of four rocker lobes 92.

FIG. 21 shows the launcher 10 in a “cocked” mode with rocker 80 in anupper barrel firing position. When manually “cocked”, that is pulled tothe rear, hammer 70 rotates about roll pin 71 and trigger pawl 66 slidesout of engagement with sear notch 73 and into engagement within searnotch 75. With trigger pawl 66 seated within sear notch 75, trigger 60is moved forward slightly within the trigger well of trigger guard 44under the force of trigger spring 64. Cocking hammer 70, alsoalternatively indexes the position of rocker 80 between firing the upperbarrel sleeve 22 and the lower barrel sleeve 22′. As hammer 70 iscocked, the bottom of rocker 80 slides along top contact edge 93 intoabutment with corner stop 94 of rocker lobe 92, which pivots rocker 80upward within the recessed pocket 79 of hammer 70. Rocker spur spring 96prevents rocker spur 90 from rotating with hammer 70 as it is cocked.

FIGS. 22 and 26 show the launcher 10 discharging the round from theupper barrel sleeve 22. When trigger 60 is pressed rearward from the“cock” mode, trigger pawl 66 is pulled out of engagement within searnotch 75 and hammer 70 is slammed forward under the force of hammerspring 74. The forward movement of hammer 70 drives upper strike face 84of rocker 80 into the firing pin 52 for the upper barrel sleeve 22,while lower strike face 86 is spaced from the firing pin 52 for thelower barrel sleeve 22′. Rocker 80 drives firing pin 52 forward, whichimpacts primer 8 discharging round 2. The position of rocker 80 pivotedupward within hammer pocket 79 caused by the abutment with rocker spur90 ensures that rocker 80 only contacts the firing pin 52 for the upperbarrel sleeve 22.

FIG. 23 shows the launcher 10 in a subsequent “cocked” mode with rocker80 in a lower barrel firing position. A subsequent, cocking of hammer 70again moves trigger pawl 66 out of engagement with sear notch 73 andinto engagement within sear notch 75; however, the bottom of rocker 70now slides off of the top contact edge 93 of one lob 92 and restsagainst the end contact edge 95 of the adjacent lob 92′, which pivotsthe rocker downward within the recessed pocket 79 of hammer 70. Rocker80 is held down in this position by spring 82. Again, rocker spur spring96 prevents rocker spur 90 from rotating with hammer 70 as it is cocked.

FIGS. 24 and 27 show the launcher 10 discharging the round from thelower barrel sleeve 22′. Now when trigger 60 is pressed rearward andhammer 70 slams forward, lower strike face 86 of rocker 80 impacts thefiring pin 52 for the lower barrel sleeve 22′ and upper strike face 84is spaced away and under the firing pin 52 for upper barrel sleeve 22.Again, the position of rocker 80 pivoted downward within hammer pocket79 caused by the abutment with rocker spur 90 ensures that rocker 80only contacts the firing pin 52 for the lower barrel sleeve 22′.

FIG. 25 shows launcher 10 back in an initial “safe/pre-cocked” or“load/unload” mode with the spent rounds 2 ready to be unloaded. After,one or in this case as illustrated, both rounds 2 have been spent,hammer 70 can be partially cocked to the “pre-cocked” or “load/unload”mode so that barrel section 20 can be opened and the spent rounds 2unloaded. Again, in this mode, trigger pawl 66 restrictively seatswithin sear notch 73, which prevents the user from accidently pressingtrigger 60 and discharging an unspent round.

One skilled in the art will note that the present invention providesseveral advantages over conventional firearms that are converted forless-lethal ballistic projectile rounds. The handgun configurationallows the launcher to be manipulated, held and fired with one hand, aswell as being conveniently carried and holstered. The over/under doublebarrel configuration provides a two shot capacity. The bodies of thereceiver and barrel sections are constructed of reinforced polymermaterials for durability and light-weight. The break-open load actionand ejector allows the launcher to be easily loaded and unloaded. Theejector provides a dual function in that it locks the barrel section inthe firing position and pulls the spent rounds from the barrel sectionto ease reloading. The fire control mechanism uses a traditional singleaction operation for simplicity of use and reliability. In addition, thefire control mechanism ensures that rounds are alternatively dischargedfrom each barrel and prevents rounds from both barrels from beingdischarged simultaneously. The design and configuration of the barrelsection and back plate ensures that the launcher only operates usingless-lethal ballistic projectile rounds and cannot be loaded or usedwith deadly firearm ammunition. In other embodiment of the launcher, theback plate can modified to accommodate standard less-lethal projectilerounds as desired.

The embodiments of the present invention herein described andillustrated are not intended to be exhaustive or to limit the inventionto the precise form disclosed. They are presented to explain theinvention so that others skilled in the art might utilize its teachings.The embodiment of the present invention may be modified within the scopeof the following claims.

I claim:
 1. A hand held launcher for use with a less-lethal ballistic projectile round, where the round includes a shell casing having an annular recess formed in a flat end around a primer and a projectile, the launcher comprising: a receiver section, the receiver section includes a handle grip and a back plate; a barrel section pivotally connected to the receiver section for movement between an open position spaced from the back plate and a closed position abutting the back plate, the barrel section includes a tubular barrel sleeve having an axial bore with a rear end for receiving the round therein, and a forward end from which the projectile is launched; and a fire control mechanism housed within the receiver for discharging the round loaded into the barrel sleeve, the receiver section and barrel section being constructed in part of a polymer material, the barrel sleeve is made of metal. 